critical asset surveillance models using electrical ... · infrared scan ultrasound scan partial...

Critical Asset Surveillance Models Using

Electrical Maintenance Safety Devices

1

Presenter:

Martin RobinsonCEO IRISS Group

Which Bulb Is Not Working??2

Functioning

CorrectlyFunctioning

Correctly

Failed System:

Does not Work

Failed System:

Too BrightFailed System:

Too Dim3

Traditional Maintenance and testing of electrical systems utilize intrusive work practices such as:

• Tightness / Torque testing• Megger / Stress testing• Circuit Testing• Load Bank Testing• Breaker and Isolator Testing• Etc…

Traditional Electrical Maintenance practices

CAST 1-4

These “Maintenance Tasks” are designed with one outcome in mind: “To confirm whether of not the circuits and connections are good and that the system meets its “Operational Requirements”.

IS THERE A BETTER WAY????

Infrared Scan

Measures temperature caused

by high resistance connections, load imbalance, etc…

Ultrasound Scan

Records Airborne Emissions at 40 kHz to identify Arcing

Tracking and Corona.

Partial Discharge

Identifies cable insulation issues in

energized systems of 5kV and above

Motor Current Analysis

Identifies faulty electrical circuits & components. Can be

completed De-energized

Ultraviolet Scan

Finds Corona issues in energized systems

of 5kV and above

Visual Inspection

Visual identification of system integrity. Can be completed

De-energized

Electrical Connections must be inspected under load

conditions to allow their condition to be validated

The Majority of Condition Based Test Equipment Require Energized systems

**NFPA 70B Recommends a Minimum of 40% Load** 5

Risk Exposure Reductions Utilizing Planned Maintenance (PM) Programs

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The blue area is the potential expense to perform repairs upon failure This amounts to millions of dollars per year not counting production losses, collateral damage or injury. The red area is the costs associated with PM / CAST programs

Risk exposure is 66% less when utilizing PM / CAST (source IEEE)

How do we start?CAST 1-7

Cable Connections Bus Bar Connections Isolator or Circuit Breaker

Connections

Identify the Components you wish to inspect

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Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis

Ultraviolet Scan Visual Inspection

Inspection Results

No Issues Found

Inspection Results

No Issues Found

Inspection Results

No Issues Found(Voltage Related,

Usually used in 5kV Systems or Above)

Inspection Results

No Issues Found

Inspection Results


Usually used in 5kV

Systems or Above)

Inspection Results

No Issues Found

Good Electrical Connection and Circuit

Test Equipment Results

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Inspection Results

Uniform heating of completed Circuit

Inspection Results

No Issues Found

Inspection Results



Inspection Results

No Issues Found

Inspection Results


Usually used in 5kV

Systems or Above)

Inspection Results

In extreme cases we may see heat damage

on cables, etc….

Overloaded Electrical Connection and Circuit


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Inspection Results

Localized heating at bolted connection

Inspection Results

May find Arcing or tracking depending on

severity of the fault

Inspection Results



Inspection Results

Inspections should show elevated

resistance reading in tested circuits.

Inspection Results


Usually used in 5kV

Systems or Above)

Inspection Results

In extreme cases we may see heat damage

on cables, etc….

High Resistance Or Loose Electrical Connection


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Inspection Results

Localized heating at Lug/cable connection.

Inspection Results

May find Arcing or tracking depending on

severity of the fault

Inspection Results



Inspection Results

Inspections should show elevated

resistance reading in tested circuits.

Inspection Results


Usually used in 5kV

Systems or Above)

Inspection Results

No Issues Found

High Resistance Or Loose Cable Lug Connection


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Inspection Results

Depending on severity level this may not produce heat….

Inspection Results

Should produce corona but is voltage

defendant

Inspection Results

TEV will be present but results are voltage

Related, Usually used in 5kV Systems or Above

Inspection Results

No Issues Found

Inspection Results

Corona will be present but results are voltage

Related, Usually used in

5kV Systems or Above

Inspection Results

In extreme cases the Partial Discharge can

be seen as a white

residue

Partial Discharge or Cable Insulation failure


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Equipment Failure Patterns

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D-I-P-F Curve

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Electrical D-I-P-F Curve

1. As much as 60% of failures & safety issues

can be prevented by making changes in

design

2. 80% or more of a facility's life cycle cost is

fixed during the plan, design, and build phases

3. 30-40% of equipment breakdowns are related

to poor equipment design or condition17

Asset Management and Design Strategies

A major part of asset design and procurement

relies heavily on the input from the Original

Equipment Manufacturer (OEM). We must consider

the OEM impact upon the ultimate design,

reliability, and success of a project. These directly

impact the following statistics:

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There are three principles of system design in high availability

engineering:

1. Elimination of single points of failure. This means

adding redundancy to the system so that failure of a

component does not mean failure of the entire system.

2. Reliable crossover. In multithreaded systems, the

crossover point itself tends to become a single point of

failure. High availability engineering must provide for

reliable crossover.

3. Detection of failures as they occur. If the two

principles above are observed, then a user may never

see a failure. But the maintenance and reliability

activities must be designed to detect early signs of

impending failure.

System Design and Reliability

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Electrical D-I-P-F Curve

CAST Technologies detect problems early

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Final Stages of Failure:All CAST inspections continue to degrade, physical signs of detection seen by operators(smell, noise, hot-to-touch, etc…)

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SummaryCritical Asset Surveillance Technologies

Critical Asset Surveillance Technologies22

CAST 1-23

CAST 1-24

Se

ve

rity

Likelihood

Risk Priority Number

CAST 1-25

CAST 1-26

Likelihood

Se

ve

rity

Online Monitoring

Monthly Inspection

Quarterly Inspection

Semi-Annual Inspection

Annual Inspection

CAST 1-27

Risk Appetite Maintenance Plan Selections

Bridging the Skills GapCAST 1-28

CAST 1-29

CAST 1-30

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Critical Asset Surveillance Technologies

(CAST)

• CAST is a risk based 100% surveillance repair model that utilizes condition based monitoring technologies.

• Potential issues can be found easily and efficiently significantly impacting the detection multiplier on the RPN calculation.

• CAST surveillance and inspection methods determine the condition of assets or systems being inspected and include but are not limited to:

• Infrared Thermography• Airborne Ultrasound• Motor Current Analysis• Partial Discharge Testing• Power Quality Management• Ultraviolet “Corona” Imaging• Vibration Analysis• Alignment Testing• Visual Inspections

Critical Asset Surveillance Technologies Overview:

CAST 1-32

Common Ways to Interact with Equipment

• Opening or closing doors

• Removing or replacing a cover

• Reaching into or leaning into equipment

• Removing or replacing internal barriers

• Operating switches or circuit breakers

• Racking a circuit breaker

• Using tools or test equipment

An “Electrical Hazard” is a state that occurs when exposed parts are present OR when you are interacting with a piece of equipment in such a way that you could be electrocuted or cause an arc flash.

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Reducing Maintenance

Induced Failures

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Ports

Ultrasound

External Voltage Indicators

MCA

Power Quality

Online Monitoring

Temperature Monitoring

Asset Tags & Monitoring

Vibration Analysis

Partial Discharge

Power Quality

Types of Electrical Maintenance Safety Devices (EMSD)

Infrared (IR) Windows

Round / Rectangular IR

Windows

Visual / IR / UV spectrums

Custom designed IR

Windows

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A Recent Emerson Study on The Effect of Regular, Skilled

Preventive Maintenance and Remote Monitoring of Critical

Power system Reliability on Mean Time Between Failures

(MTBF) showed the following Results:

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The Asset MTBF is increased by 51

times by inspecting once per quarter

Source: The Effect of Regular, Skilled preventive Maintenance and Remote Monitoring on Cri tical Power system Reliability

Total Cost of Asset Ownership

Direct (Visible) Costs• Acquisition• Research• Design• Production and Test• Construction

Indirect (Invisible) Costs• Operations (Personnel, Facilities, Utilities)• Maintenance, Testing and Support• Spares and Inventory• Training• Software• Disposal

15%

85%

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Total Cost of Asset Ownership

Direct (Visible) Costs• Acquisition• Research• Design• Production and Test• Construction

Indirect (Invisible) Costs• Operations (Personnel, Facilities, Utilities)• Maintenance, Testing and Support• Spares and Inventory• Training• Software• Disposal

15%

Up to 75%

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The Use of EMSD CAST Programs Deliver the Following:

• Risk exposure is 66% less when utilizing CAST / PM programs

• RPN significantly reduced through improved fault detection techniques

• Simplified inspection programs bridge the skills gap• Significant impact on the Total Cost of Ownership by

reducing indirect costs associated with up to 75% of TCO41

The Use of EMSD CAST Programs Deliver the Following:

• MTBF is significantly improved adding to increased uptime and decreased downtime.

• Remove maintenance induced failures by simplifying energized maintenance inspection processes

• Increased ROI On CAST equipment and training

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